Nonwoven substrate comprising fibers comprising an engineering thermoplastic polymer

ABSTRACT

A nonwoven substrate comprising a polyolefin and an engineering thermoplastic polymer. The engineering thermoplastic polymer may be present in the nonwoven substrate at a level of between about 1% and about 20% by weight of the nonwoven substrate. The layer of fibers is free of a compatibilizer.

FIELD

The present disclosure generally relates to a nonwoven substratecomprising a layer of fibers, wherein the fibers comprise a polyolefinand an engineering thermoplastic polymer, wherein the layer of fibers isfree of a compatibilizer.

BACKGROUND

Engineering Thermoplastic Polymers (ETPs) are a group of materials thathave better mechanical and/or thermal properties than the more widelyused commodity thermoplastics such as polypropylene (PP) or polyethylene(PE). Presently, ETPs are typically produced in smaller quantities andtend to be used in smaller objects or low-volume applications, such asmechanical parts, rather than for bulk and high-volume ends, such ascontainers and packaging. However, it has been discovered that inclusionof low quantities of ETPs into commodity thermoplastic polymers mayimprove functionality and mechanical properties of material, thusproviding product improvements and benefits.

Typically, the combination of a polyolefin and an ETP requires thepresence of a compatibilizer due to differences in their solubilityparameters and immiscibility of such polymers. Thus, typically,compatibilizers are used to improve interfacial adhesion of twoimmiscible polymers. Compatibilizers are costly and inclusion mayincrease the overall cost of nonwoven substrates.

Therefore, the present disclosure provides nonwoven substratescomprising at least a layer of fibers, wherein the fibers comprise apolyolefin and an engineering thermoplastic polymer without the presenceof a compatibilizer. The present disclosure also provides a laminatecomprising nonwoven substrates comprising a layer of fibers, wherein thefibers comprise a polyolefin and an engineering thermoplastic polymerand an additional material.

SUMMARY

In one form, the present disclosure is directed, in part, to a nonwovensubstrate comprising a layer of fibers. The fibers may comprise apolyolefin and an engineering thermoplastic polymer, and the engineeringthermoplastic polymer may be present in the range of from about 1% toabout 20% by weight of the nonwoven substrate. The layer of fibers maybe free of a compatibilizer.

In another form, the present disclosure is directed, in part, to anonwoven substrate comprising essentially of a layer of fiberscomprising a polyolefin and an engineering thermoplastic polymer. Theengineering thermoplastic polymer may be present in the range of fromabout 1% to about 20% by weight of the nonwoven substrate.

In still another form, the present disclosure is directed, in part, to alaminate comprising a nonwoven substrate comprising a layer of fibers,the fibers comprising a polyolefin and an engineering thermoplasticpolymer. The engineering thermoplastic polymer may present in the rangeof from about 1% to about 20% by weight of the nonwoven substrate. Thelayer of fibers may be free of a compatibilizer. The laminate mayfurther comprise an additional material joined to a side of the nonwovensubstrate.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of non-limiting embodiments of the disclosuretaken in conjunction with the accompanying drawings, wherein:

FIG. 1 an SEM of a cross section of PLA/PP nonwoven fibers.

FIG. 2 is a graph of Average MD Tensile Modulus (25 gsm Basis Weight) ofvarious nonwoven substrates of the present disclosure.

FIG. 3 is a graph of Indexed MD Tensile Modulus of various nonwovensubstrates of the present disclosure.

FIG. 4 is a graph of Average CD Elongation at Break of various nonwovensubstrates of the present disclosure.

FIG. 5 is a graph of MD Tensile Modulus/Basis Weight Ratio of variousnonwoven substrates of the present disclosure.

FIG. 6 is a graph of CD Tensile of various nonwoven substrates of thepresent disclosure.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, and use of the nonwoven substrates describedherein. One or more examples of these non-limiting embodiments areillustrated in the accompanying drawings. Those of ordinary skill in theart will understand that the nonwoven substrates described herein andillustrated in the accompanying drawings are non-limiting exampleembodiments and that the scope of the various non-limiting embodimentsof the present disclosure are defined solely by the claims. The featuresillustrated or described in connection with one non-limiting embodimentmay be combined with the features of other non-limiting embodiments.Such modifications and variations are intended to be included within thescope of the present disclosure.

As used herein, the term “absorbent article(s)” refers to consumerproducts whose primary function is to absorb and retain bodily exudatesand wastes. Absorbent articles may refer to pants, taped diapers, adultincontinence products, and/or sanitary napkins (e.g., feminine hygieneproducts). The terms “diaper” and “pants” are used herein to refer toabsorbent articles generally worn by infants, children, and incontinentpersons about the lower torso. The term “disposable” is used herein todescribe absorbent articles which generally are not intended to belaundered or otherwise restored or reused as an absorbent article (e.g.,they are intended to be discarded after a single use and may also beconfigured to be recycled, composted, or otherwise disposed of in anenvironmentally compatible manner).

“Bicomponent” refers to fiber having a cross-section comprising twodiscrete polymer components, two discrete blends of polymer components,or one discrete polymer component and one discrete blend of polymercomponents. “Bicomponent fiber” is encompassed within the term“Multicomponent fiber.” A Bicomponent fiber may have an overall crosssection divided into two or more subsections of the differing componentsof any shape or arrangement, including, for example, coaxialsubsections, core-and-sheath subsections, side-by-side subsections,radial subsections, etc.

“Monocomponent” refers to fiber formed of a single polymer component orsingle blend of polymer components, as distinguished from Bicomponent orMulticomponent fiber.

“Multicomponent” refers to fiber having a cross-section comprising morethan one discrete polymer component, more than one discrete blend ofpolymer components, or at least one discrete polymer component and atleast one discrete blend of polymer components. “Multicomponent fiber”includes, but is not limited to, “Bicomponent fiber.” A Multicomponentfiber may have an overall cross section divided into subsections of thediffering components of any shape or arrangement, including, forexample, coaxial subsections, core-and-sheath subsections, side-by-sidesubsections, radial subsections, etc.

As used herein, the term “carded fibers” refer to fibers that are of adiscrete length which are sorted, separated, and at least partiallyaligned by a carding process. For example, a carded substrate refers toa substrate that is made from fibers which are sent through a combing orcarding unit, which separates or breaks apart and aligns the fibers in,e.g., the machine direction to form a generally machinedirection-oriented fibrous nonwoven web. Carded fibers may or may not bebonded after being carded

As used herein, the term “film” refers generally to a relativelynonporous material made by a process that includes extrusion of, e.g., apolymeric material through a relatively narrow slot of a die. The filmmay be impervious to a liquid and pervious to an air vapor, but need notnecessarily be so. Suitable examples of film materials are described inmore detail hereinbelow.

As used herein, the term “joined” encompasses configurations wherein anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations wherein an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

As used herein, the term “laminate” refers to an element that has atleast one nonwoven substrate joined to at least one additional material.The additional material may be a nonwoven, film, elastomeric, ornon-elastomeric material. The laminate may have more than one nonwovensubstrate joined to the at least one additional material. The nonwovensubstrates may be joined to the additional material using bondingtechniques or gluing techniques, for example.

As used herein, the term “layer” refers to a sub-component or element ofa substrate. A “layer” may be in the form of a plurality of fibers madefrom a single beam on a multibeam nonwoven machine (for example aspunbond/meltblown/spunbond nonwoven substrate includes at least onelayer of spunbond fibers, at least one layer of meltblown fibers, and atleast one layer of spunbond fibers) or in the form of a film extruded orblown from a single die.

As used herein, the term “machine direction” or “MD” is the directionthat is substantially parallel to the direction of travel of a substrateas it is made. Directions within 45 degrees of the MD are considered tobe machine directional. The “cross direction” or “CD” is the directionsubstantially perpendicular to the MD and in the plane generally definedby the web. Directions within 45 degrees of the CD are considered to becross directional.

As used herein, the term “meltblown fibers” refers to fibers made via aprocess whereby a molten material (typically a polymer), is extrudedunder pressure through orifices in a spinneret or die. High velocity hotair impinges upon and entrains the filaments as they exit the die toform filaments that are elongated and reduced in diameter and arefractured so that fibers of generally variable but mostly finite lengthsare produced. This differs from a spunbond process whereby thecontinuity of the filaments is preserved along their length. An examplemeltblown process is found in U.S. Pat. No. 3,849,241 to Buntin et al.

As used herein, the term “nonwoven” refers to a porous, fibrous materialmade from continuous (long) filaments (fibers) and/or discontinuous(short) filaments (fibers) by processes such as, for example,spunbonding, meltblowing, carding, and the like. Nonwoven webs do nothave a woven or knitted filament pattern.

As used herein, the term “pant” refers to disposable absorbent articleshaving a continuous perimeter waist opening and continuous perimeter legopenings designed for infant, child, or adult wearers. A pant may beconfigured with a continuous or closed waist opening and at least onecontinuous, closed, leg opening prior to the absorbent article beingapplied to the wearer. A pant may be preformed by various techniquesincluding, but not limited to, joining together portions of theabsorbent article using any refastenable and/or permanent closure member(e.g., seams, heat bonds, pressure welds, adhesives, cohesive bonds,mechanical fasteners, etc.). A pant may be preformed anywhere along thecircumference of the absorbent article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed). A pant may be opened about one or both of the side seams andthen refastened. Example pants in various configurations are disclosedin U.S. Pat. Nos. 5,246,433, 5,569,234, 6,120,487, 6,120,489, 4,940,464,5,092,861, 5,897,545, 5,957,908, and U.S. Patent Publication No.2003/0233082.

As used herein, the term “spunbond fibers” refers to fibers made via aprocess involving extruding a molten thermoplastic material as filamentsfrom a plurality of fine, typically circular, capillaries of aspinneret, with the filaments then being attenuated by applying a drawtension and drawn mechanically or pneumatically (e.g., mechanicallywrapping the filaments around a draw roll or entraining the filaments inan air stream). The filaments may be quenched by an air stream prior toor while being drawn. The continuity of the filaments is typicallypreserved in a spunbond process. The filaments may be deposited on acollecting surface to form a web of randomly arranged substantiallycontinuous filaments, which may thereafter be bonded together to form acoherent nonwoven layer. Example spunbond process and/or webs formedthereby may be found in U.S. Pat. Nos. 3,338,992, 3,692,613, 3,802,817,4,405,297, and 5,665,300.

As used herein, the term “substrate” refers to an element that includesat least a fibrous layer and has enough integrity to be rolled, shippedand subsequently processed (for example a roll of a substrate may beunrolled, pulled, taught, folded and/or cut during the manufacturingprocess of an absorbent article having an element that includes a pieceof the substrate). Multiple layers may be bonded together to form asubstrate.

As used herein, the term “taped diaper” refers to disposable absorbentarticles having an initial front waist region and an initial rear waistregion that are not fastened, pre-fastened, or connected to each otheras packaged, prior to being applied to the wearer. A taped diaper may befolded about its lateral central axis with the interior of one waistregion in surface to surface contact with the interior of the opposingwaist region without fastening or joining the waist regions together.Example taped diapers disclosed in various suitable configurations areillustrated in U.S. Pat. Nos. 5,167,897, 5,360,420, 5,599,335,5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537, 6,118,041,6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787, 6,617,016,6,825,393, and 6,861,571.

Modern absorbent articles such as taped diapers, pants, sanitary tissueproducts, and/or adult incontinence products include many elements thatare at one time or another in contact with the caregiver or user's skin.The use of nonwoven substrates is particularly advantageous in suchelements due to the soft feel and the cloth-like appearance theyprovide. Some modern disposable absorbent articles are also designed toprovide an underwear-like fit. Conventional nonwoven substrates maycomprise combinations of polyolefins, such as polypropylene and/orpolyethylene. Other conventional nonwoven substrates may comprise acombination of polyolefins and engineering thermoplastic polymers(ETPs). When high concentrations of ETPs are present in a nonwovensubstrate in combination with a polyolefin, a compatibilizer is oftennecessary due to differences in their solubility parameters andimmiscibility of such polymers. Thus, typically, compatibilizers areused to improve interfacial adhesion of two immiscible polymers.Compatibilizers are costly and inclusion may increase the overall costof nonwoven substrates.

Since manufacturers of nonwoven substrates and products comprising thenonwovens substrates are under continuous pressure to reducemanufacturing cost and minimize manufacturing waste, it is believed thatthe nonwoven substrates disclosed hereinafter may be a suitablealternative to conventional nonwoven substrates, having improved tensileproperties and reduced manufacturing costs, without the presence ofcompatibilizers.

Further, it is believed the nonwoven substrates of the present inventionmay provide an increase in nonwoven CD elongation, thus improvedextensibility of substrate. Also, it is believed the nonwoven substratesof the present invention may provide an increase in MD Tensile Modulus,thus enabling substrate basis weight reduction without compromisingnonwoven converting or increased roll neck-down during unwinding andsplicing process during absorbent article manufacturing. The foregoingconsiderations are addressed by the present disclosure, as will be clearfrom the detailed disclosure.

The nonwoven substrate of the present invention may be useful in anabsorbent article such as a pant, a taped diaper, a feminine hygieneproduct, and an adult incontinence product

The nonwoven substrate may have a basis weight of between about 2 g/m²(gsm) and about 50 g/m², between about 4 g/m² and about 25 g/m², betweenabout 5 g/m² and about 20 g/m², about 13 g/m², about 17 g/m², or about20 g/m², specifically reciting all 0.1 g/m² increments within the rangesspecified in this paragraph. The nonwoven substrate may have a basisweight of less than about 50 g/m², less than about 25 g/m², greater thanabout 2 g/m², greater than about 5 g/m², specifically reciting all 0.1g/m² increments within the ranges specified in this paragraph. The basisweight of any of the substrates described herein may be determined usingInternational Nonwovens and Disposables Association (“INDA”) method WSP130.1(05). The basis weight of any of the individual layers describedherein, and which together form a substrate, may be determined byrunning in sequence each of the fiber forming beams that are used toform separate layers and then measuring the basis weight of theconsecutive formed layer(s) according to INDA method WSP 130.1(05). Thesubstrate may be harvested from a finished product by any method thatdoes not damage the specimen (e.g. solvent or freeze spray).

It may be advantageous to provide the nonwoven substrate with at leasttwo layers of fibers (each having top and bottom surfaces). The secondlayer of fibers may be free of engineering thermoplastic polymers. Inanother embodiment, the second layer of fibers may comprise engineeringthermoplastic polymers. The nonwoven substrate may comprise at least onelayer of spunbond fibers. The nonwoven substrate may comprise at leasttwo layers of spunbond fibers. Further, the nonwoven substrate maycomprise at least one layer of carded fibers. Further, the nonwovensubstrate may comprise at least one layer of meltblown fibers. Further,the nonwoven substrate may comprise at least one layer of microfibers.In an embodiment, any of the layers of fibers, including spunbondfibers, carded fibers, meltblown fibers, or microfiberes may comprise orbe made of monocomponent, bicomponent, or multicomponent fibers.

In an embodiment, the nonwoven substrate may comprise a polyolefin, suchas polypropylene or polyethylene. Polyolefins useful in the presentdisclosure may be present at a level, by weight of the nonwovensubstrate, of between about 80% and about 99%, of between about 90% andabout 99%, of between about 95% and about 99%. Polyolefins useful in thepresent disclosure may be present at a level, by weight of the nonwovensubstrate, of greater than about 80%, greater than about 90%, greaterthan about 95%, specifically reciting all 0.1% increments within theabove-specified ranges.

The nonwoven substrate may further comprise an engineering thermoplasticpolymer. Some engineering thermoplastic polymers that may be used in thepresent disclosure include Polyesters, Aliphatic Polyesters such aspolylactic acid, Aromatic Polyesters, Polyamides, Polyimides, acrylates,methacrylates, styrenics, Polycarbonates (PC), Polytetrafluoroethylene(PTFE/Teflon), Acrylonitrile butadiene styrene (ABS), Polyphenyleneoxide (PPO), Polysulphone (PSU), Polyetherketone (PEK),Polyetheretherketone (PEEK), Polyphenylene sulfide (PPS),Polyoxymethylene plastic (POM/Acetal), and polyvinyl chloride or amixture of two or more of the mentioned compounds, may be used.Engineering thermoplastic polymers useful in the present disclosure maybe present at a level, by weight of the nonwoven substrate, of betweenabout 1% and about 20%, of between about 1% and about 10%, of betweenabout 2% and about 7%, of between about 3% and about 5%. Engineeringthermoplastic polymers useful in the present disclosure may be presentat a level, by weight of the nonwoven substrate, of less than about 20%,less than about 15%, less than about 10%, less than about 7%, less thanabout 5%, specifically reciting all 0.1% increments within theabove-specified ranges.

The nonwoven substrate may comprise fibers comprising an engineeringthermoplastic polymer and separate fibers comprising a polyolefin.Further, the nonwoven substrate may comprise fibers comprising both anengineering thermoplastic polymer and a polyolefin.

The nonwoven substrate of the present disclosure may not comprise acompatibilizer. Alternatively, the nonwoven substrate of the presentdisclosure may consist essentially of a layer of fibers comprising apolyolefin and an engineering thermoplastic polymer. Compatibilizersoften used in nonwoven substrates include, but are not limited toLotader AX8840, available from Arkema (copolymer of ethylene andglycidyl methacrylate; MFR 5 g/10 min); Fusabond M603, available fromDupont (random ethylene copolymer with a monomer classified as being amaleic anhydride equivalent; MFR 25 g/10 min); Elvaloy 1224AC, availablefrom Dupont (copolymer of ethylene and methyl acrylate; MFR 2 g/10 min);Metocene MF650W, available from Lyondell, (maleated polypropylene, MFR500 g/10 min).

Fibers of the nonwoven substrates of the present disclosure may have adiameter. In an embodiment, the diameter of the fibers may be betweenabout 1 micron and about 50 microns, between about 10 microns and about40 microns, between about 15 microns and about 35 microns. The diameterof the fibers may be less than about 50 microns, less than about 40microns, less than about 35 microns, less than about 25 microns. Thediameter of the fibers may be greater than about 1 micron, greater thanabout 10 microns, greater than about 15 microns.

In an embodiment, the nonwoven substrate may comprise a polyolefin, anengineering thermoplastic polymer, and a plasticizer. Plasticizers thatmay be used in the present disclosure include Citrates, Adipates,Esters, Glycerols, oils, phthalate free plasticizers, bio-basedplasticizers, and combinations thereof. Plasticizers useful in thepresent disclosure may be present at a level, by weight of the nonwovensubstrate, of between about 1% and about 20%, between about 3% and about18%, between about 5% and about 15%. Plasticizers useful in the presentdisclosure may be present at a level, by weight of the nonwovensubstrate, of less than about 20%.

In a further embodiment, the nonwoven substrate may be part of alaminate, such that the nonwoven substrate is bonded to an additionalmaterial. In such an embodiment, the nonwoven substrate comprises atleast one layer of spunbond fibers having top and bottom surfaces suchthat the bottom surface of the layer is bonded to top surface or side ofthe additional material via an adhesive. The nonwoven substrate maycomprise additional layers such as at least one layer of meltblownfibers (having top and bottom surfaces) and at least one layer ofspunbond fibers (also having top and bottom surfaces) and at least onelayer of carded fibers (having top and bottom surfaces) and at least onelayer of microfibers (having top and bottom surfaces). The top surfaceof the layer faces the bottom surface of the layer and the top surfaceof the layer faces the bottom surface of the layer.

In one embodiment, the additional material may be an elastomericmaterial, an elastomeric nonwoven substrate, an elastomeric film, or anonwoven material. The elastomeric material in the form of a film mayinclude a core layer that may be directly bonded to the spunbond layerof the nonwoven substrate. A core layer may be directly bonded to thenonwoven substrate by extruding the elastomeric material directly ontothe nonwoven substrate. An adhesive may be added onto the contactsurface of the extruded elastomeric material to increase the bondstrength between the elastomeric material and the nonwoven substrate. Inone embodiment, the elastomeric material may be a non-elastomeric film.

In an embodiment, any of the previously discussed nonwoven layers ofspunbond fibers or meltblown fibers may comprise or be made ofbicomponent or multicomponent fibers comprising one or morethermoplastic polymers and one or more ETPs. In some embodiments, onlythe spunbond fibers may comprise or be made of bicomponent ormulticomponent fibers. The fibers may each comprise a core and a sheath.The core may be formed from a composition comprising one or morethermoplastic polymers and one or more ETPs. In an embodiment, thethermoplastic polymer may comprise or be a polyolefin, such aspolypropylene, and ETP may comprise or be Polylactic acid. The sheathmay also be formed from a composition comprising another thermoplasticpolymer and another ETP. The sheath may comprise one or morethermoplastic polymers, such as a polyolefin, and may have little (e.g.,less than about 20%, less than about 5%, or less than about 3% or noETP). The polyolefin used to make the core may be different than or thesame as the polyolefin used to make the sheath. If two polyolefins areused, both polyolefins may have different melt temperatures anddifferent tensile properties. In an embodiment, each of the twopolyolefin polymers used to form the bicomponent fibers may besubstantially non-elastic. The two polyolefins may be polypropylene andpolyethylene, for example. In an embodiment, the sheath sheath maycontain at least about 1% of an ETP, a thermoplastic polymer of thesheath may comprise polyethylene, and a thermoplastic polymer of thecore may comprise polypropylene.

Bicomponent or multicomponent fibers with a core comprising the ETP anda sheath free of, or substantially free of, the ETP, may be advantageousin stabilizing melt spinning and continuous fiber formation in case ofspunbond process. In an embodiment, a nonwoven substrate in astretchable laminate may comprise two or more spunbond layers therein.The spunbond layers that will contact the absorbent articlemanufacturing equipment may contain little or no ETP, while otherspunbond layers either in the center of the nonwoven substrate oradjacent to the elastomeric material may comprise between about 1% andabout 20% by weight of the ETP. This type of layering of the spunbondlayers within the stretchable laminates may help reduce contamination onabsorbent article manufacturing equipment caused by potential exposedETP's since the spunbond layers contacting the absorbent articlemanufacturing equipment will have little or no ETP's. Such positioningof the spunbond layers within stretchable laminates and/or nonwovensubstrates also applies in the same way to the monocomponent fibers(i.e., thermoplastic polymer and ETP without a core/sheath) discussedherein. In an embodiment of a bicomponent fiber, the core may comprise afirst amount, by weight, of the ETP and the sheath may comprise a secondamount, by weight, of the ETP. The first amount may be the same as ordifferent than the second amount. Further details regarding bicomponentor multicomponent fibers and methods of making the same may be found inU.S. Patent Application Publ. Nos. 2009/0104831, 2010/0262107,2010/0262105, 2010/0262102, and 2010/0262103.

In an embodiment, a bicomponent or multicomponent fiber may comprise acore formed from a composition comprising one or more elastomericthermoplastic polymers, such as VISTAMAXX® (available from ExxonMobil,Houston, Tex.), and/or a polylactic acid, for example. The elastomericthermoplastic polymers, when used to form a core, may provide betterstretch properties than typical thermoplastic polymers. Suitableelastomeric thermoplastic polymers are disclosed in U.S. Pat. No.7,491,770 to Autran et al. Other suitable elastomeric thermoplasticpolymers are known to those of skill in the art. The composition mayalso comprise polypropylene and an ETP in addition to the elastomericthermoplastic polymer(s). The sheath of the fiber may be formed from acomposition comprising one or more thermoplastic polymers and one ormore ETP's. The ETP(s) may be present in the composition at a levelbetween about 1% and about 20% by weight of the composition,specifically reciting all 0.5% increments within the above-specifiedranges. In an embodiment, the thermoplastic polymer may be polypropyleneand the ETP may be polylactic acid. The fibers of the present disclosure(e.g., spunbond fibers) may comprise these bicomponent or multicomponentfibers.

In an embodiment, the nonwoven material may be used in an absorbentarticle such as a pant or a taped diaper. The absorbent article maycomprise a liquid pervious layer, a liquid impervious layer, anabsorbent core disposed between the liquid pervious layer and the liquidimpervious layer. The absorbent article may also comprise a stretchablelaminate, such as side panels or ears, joined to any of the liquidpervious layer, the liquid impervious layer, and the absorbent core. Oneor both of the side panels or ears may comprise a fastening element,such as a portion of a hook and loop fastener. The fastening element maybe engagable with a landing zone when the absorbent article is donned ona wearer. The nonwoven substrates, in some embodiments, may function astopsheets, backsheets, apertured topsheets, acquisition layers, portionsof wings of sanitary napkins, and portions of side panels, ears, and/orfasteners of diapers, for example. Other uses on other nonwovensubstrate containing products are also envisioned and are within thescope of the present disclosure.

Compounding Process:

Lyondell Baselle PH835 Polypropylene (PP) Polymer with varying amountsof NatureWorks 6202D PolyLactic Acid (PLA) Polymer are used for thesestudies. The PLA material is dried at 80 degree Celsius in high vacuumoven for greater than 24 hours and stored in a dry box. Both PP and PLAmaterials are weighed individually and dry blended to homogeneity. Theblends are fed into a Berstorff ZE25 Twin Screw Co-rotating extruderusing a fixed feed rate setting. Extruded strands are passed through awater trough for cooling, followed by passing through an air amplifierfor air wiping the water off of strands. The strands are cut inpelletizer and collected in a 5 gallon bucket.

The Compounding extruder settings are as follows:

Feed Zone 149 F, Z2 320 F, Z3 330 F, Z4-Z6 340 F, and Z7-Z8 350 F. ScrewRPM set at 275 rpm, resulting in a Head melt temperature of 355 F and ahead pressure of 364 psi. The vibrational material feeder is set to75-80% of full scale, resulting in an approximate feed rate of 7 g/sec.

Three blends are compounded:

Example 1

Blend 1 comprises 99% PH835 PP and 1% 6202D PLA (w/w)

Example 2

Blend 2 comprises 97% PH835 PP and 3% 6202D PLA (w/w)

Example 3

Blend 3 comprises 95% PH835 PP and 5% 6202D PLA (w/w)

PLA 6202D can be obtained from NatureWorks LLC, 15305 Minnetonka Blvd.,Minnetonka, Minn. 55345.

Polypropylene Pro-fax PH835 can be obtained from LyondellBasellIndustries Holdings, Equistar Chemicals LP 11530 Northlake DriveCincinnati, Ohio 45249.

Spunbond Nonwoven Process:

Fibers for this process are made by 50/50 sheath/core spinneretsconfiguration where both sheath and core have the same materialscomposition. Spunbond nonwovens are made by the porous collection beltand adjusting the belt speed to target 25 grams per square meter (gsm).The collected fibers are first passed through a heated press roll at 75degrees Celsius at 20 psi (pounds per square inch) and then a heatedcalendering system for the final thermal point bonding, followed bywinding the continuous spunbond nonwoven onto a roll for later propertymeasurements. The heated calendering system includes a heated engravedroll and heated smooth roll. The heated engraved roll has a raisedbonding area. The calender roll pressure is held constant at 20 psi andthe line speed of the forming belt is held constant at 40 meters perminute. The specific fibers and the processes for making them are shownbelow.

Sheath Extruder Core Extruder Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2Zone 3 Zone 4 Temp Temp Temp Temp Temp Temp Temp Temp Sheath Core [° C.][° C.] [° C.] [° C.] [° C.] [° C.] [° C.] [° C.] PH835 PH835 180 189 210220 180 190 209 220 Ex. 1 1% PLA 180 189 210 220 180 190 211 220 1% PLAEx. 2 3% PLA 180 190 210 220 180 190 210 220 3% PLA Ex. 3 5% PLA 180 189210 220 180 190 209 220 5% PLA

Embodiments of the nonwoven substrate of the present disclosure aretested and various properties are compared to a nonwoven substrate nothaving any engineering thermoplastic polymers within fibers of thenonwoven substrate. In the examples below, the engineering thermoplasticpolymer (ETP) tested include varying levels of polylactic acid (PLA).

EXAMPLES

CD MD CD MD Average MD Basis Fiber Peak Peak Elongation ElongationTensile Modulus Wt Diameter Load Load at Break at Break of Nonwoven MDTensile Resin (gsm) (um) (N) (N) (%) (%) (N/mm) Modulus/BW 100% PP 25 2012.13 19.79 66.02 65.24 3.36 0.13 0% PLA Example 1 25 20 13.54 22.866.62 65.69 3.93 0.16 1% PLA Example 2 25 20 11.4 20.7 81.61 76.33 4.310.17 3% PLA Example 3 25 20 12.46 18.06 108.73 93.88 5.00 0.20 5% PLA

FIG. 1 shows a cross section of PLA/PP nonwoven fibers via ScanningElectron Microscopy (SEM). PLA domains are best determined by visualinspection under scanning electron microscopy. Nonwoven fibers arecross-sectioned using a microtome blade and liquid nitrogen to assist inthe cut quality. The fiber sample may be first dipped in liquid Nitrogenand removed. While still extremely cold, the microtome blade is used toquickly cut along the CD thus exposing a cross section of the fibers.The cross section is then mounted into a split mount SEM mount and maybesputter coated with a thin layer of gold. The cross section is thenexamined under 500×-4000× magnification to look for the presence ofdiscrete PLA domains. The SEM equipment may be a Hitachi TM-1000.

As indicated in FIG. 1, PLA does not mix with the PP matrix, even aftercompounding and fiber spinning PLA is dispersed within the polyolefinand is visible even at lower concentrations.

Methods:

All tensile measurements are measured by the INDA WSP 110.4 (05) (OptionA) tensile testing method with following revisions:

Sample size: 2″ gauge×1″ widthCrosshead speed: 50 mm/min

MD Tensile Modulus of Nonwovens are measured by defining the maximumslope of the initial (<20% strain) portion of the tensile curve, whereslope is defined as the change in force divided by the change indisplacement and has units of N/mm. This modulus represents the initialresistance of the nonwoven to tensile deformation. The higher themodulus, the greater the nonwoven's resistance to deformation (i.e., the“stiffer” it is).

Indexed MD tensile modulus=((MD tensile modulus of nonwoven y)−(MDtensile modulus of nonwoven x)/MD tensile modulus of nonwoven x)×100;where nonwoven x comprises of 0% PLA resin and nonwoven y comprise of 1,3 or 5% PLA resin.

Any substrate being tested may be harvested from a finished product byany method that does not damage the specimen (e.g. solvent or freezespray).

Nonwoven substrates of the present disclosure comprising engineeringthermoplastic polymers have improved tensile properties versus nonwovenswithout the engineering thermoplastic polymers.

As shown in FIG. 2, nonwoven substrates of the present disclosure mayhave an average MD Tensile Modulus, at a constant basis weight of 25gsm, of greater than about 3.5, greater than about 3.75, greater thanabout 4.00 N/mm.

As shown in FIG. 3, nonwoven substrates of the present disclosure havingengineering thermoplastic polymers may have an indexed MD TensileModulus compared to nonwovens without engineering thermoplastic polymersthat is greater than about 20%, greater than about 30%, greater thanabout 40%.

Further, as shown in FIG. 4, nonwoven substrates of the presentdisclosure comprising engineering thermoplastic polymers may have a CDElongation at Break of greater than about 65%, greater than about 70%,greater than about 75%, greater than about 80%.

Also, as shown in FIG. 5, nonwoven substrates of the present disclosurecomprising engineering thermoplastic polymers may have MD TensileModulus to nonwoven substrate basis weight ratio of from about 0.10 toabout 1.0, from about 0.12 to about 0.50, from about 0.15 to about 0.4,greater than about 0.10, greater than about 0.12, greater than about0.15.

FIG. 6 further shows that CD Tensile improves with inclusion ofengineering thermoplastic polymers.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany embodiment disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such embodiment. Further, to the extent that any meaningor definition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications may be made withoutdeparting from the spirit and scope of the present disclosure. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. A nonwoven substrate comprising: a layer offibers, wherein the fibers comprise a polyolefin and an engineeringthermoplastic polymer, wherein the engineering thermoplastic polymer ispresent in the range of from about 1% to about 20% by weight of thenonwoven substrate, and wherein the layer of fibers is free of acompatibilizer.
 2. The nonwoven substrate of claim 1, wherein theengineering thermoplastic polymer is present in the range of from about1% to about 10% by weight of the nonwoven substrate.
 3. The nonwovensubstrate of claim 1, wherein the engineering thermoplastic polymer ispresent in the range of from about 2% to about 7% by weight of thenonwoven substrate.
 4. The nonwoven substrate of claim 1, wherein theengineering thermoplastic polymer comprises a component selected fromthe group consisted of polylactic acid (PLA), Polyesters, Polyamides,Polyimides, acrylates, methacrylates, styrenics, Polycarbonates (PC),Polytetrafluoroethylene (PTFE/Teflon), Acrylonitrile butadiene styrene(ABS), Polyphenylene oxide (PPO), Polysulphone (PSU), Polyetherketone(PEK), Polyetheretherketone (PEEK), Polyphenylene sulfide (PPS),Polyoxymethylene plastic (POM/Acetal), polyvinyl chloride, and mixturesthereof.
 5. The nonwoven substrate of claim 1, wherein the engineeringthermoplastic polymer comprises polylactic acid.
 6. The nonwovensubstrate of claim 1, wherein the polyolefin comprises polypropylene. 7.The nonwoven substrate of claim 1, wherein the polyolefin comprisespolyethylene.
 8. The nonwoven substrate of claim 1, further comprising aplasticizer.
 9. The nonwoven substrate of claim 8, wherein theplasticizer is present in the range of from about 1% to about 20% byweight of the nonwoven substrate.
 10. The nonwoven substrate of claim 8,wherein the plasticizer is selected from the group consisted ofCitrates, Adipates, Esters, Glycerols, oils, phthalate freeplasticizers, bio-based plasticizers, and mixtures thereof.
 11. Thenonwoven substrate of claim 1, comprising a second layer of fibers freeof the engineering thermoplastic polymer.
 12. The nonwoven substrate ofclaim 1 wherein the nonwoven substrate is selected from the groupconsisting of spunbond, carded, meltblown fibers, and microfibers. 13.The nonwoven substrate of claim 1 wherein the nonwoven substrate isselected from the group consisting of monocomponent fibers, bicomponentfibers, and multicomponent fibers.
 14. The nonwoven substrate of claim 1having a basis weight of less than about 50 gsm.
 15. The nonwovensubstrate of claim 1, wherein the average MD Tensile Modulus is greaterthan about 3.5 N/mm.
 16. The nonwoven substrate of claim 1, wherein theindexed MD Tensile Modulus is greater than about 20% higher than anonwoven substrate not comprising the engineering thermoplastic polymer.17. The nonwoven substrate of claim 1, wherein the ratio of MD TensileModulus to basis weight of the nonwoven substrate is from about 0.10 toabout 1.0.
 18. The nonwoven substrate of claim 1, wherein the CDElongation at Break is greater than about 65%.
 19. A nonwoven substrateconsisting essentially of: a layer of fibers, wherein the fiberscomprise a polyolefin and an engineering thermoplastic polymer, whereinthe engineering thermoplastic polymer is present in the range of fromabout 1% to about 20% by weight of the nonwoven substrate.
 20. Alaminate comprising: a nonwoven substrate comprising a layer of fibers,wherein the fibers comprise a polyolefin and an engineeringthermoplastic polymer, wherein the engineering thermoplastic polymer ispresent in the range of from about 1% to about 20% by weight of thenonwoven substrate, and wherein the layer of fibers is free of acompatibilizer; and an additional material, wherein the nonwovensubstrate is joined to a side of the additional material.
 21. Thenonwoven substrate of claim 1, wherein the nonwoven substrate is presentin an absorbent article selected from the group consisting of a pant, ataped diaper, a feminine hygiene product, and adult incontinenceproduct.